MANUFACTURING PROCESS

ARTICLE
2018
By: Rino Andias Anugraha and Assistant Team
Telkom University

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 Manufacturing Process Laboratory Assistants 2018/2019

Audrey Rahmanti Unadi Aldyan Nurfaizi B. Tau

Aufa Rinaldo Alia Agistina
Dimas Fathurrahman Anak Agung Sri Nandini
Evita Rengganis Anggit Pratama
Fahreza Fadhil Hakeki Bagas Arganto P
Fildzah Fajrina Bela Pitria Hakim
FM Anggra Mandala Putra Damario Haznam
Husein Bimantoro Farras Burhanuddin
Lailatul Fitri Gitanjali Widayu Diatri
Nurul Farhana Mario Adiprana Muki
Maulidan Khoir Nafisha Herma Hanifha
Muhammad Ichsan Nurliyan Pangestu Rizky Purnama
Patricia Amelia Sabrina Diana Pratiwi
Putu Ayu Anggrasari Wirawardani Satria Rahmadani Putra
Raihan Muhammad Faizal Sri Yuzarnimar
Sarah Wahyuni Tri Maisyah Nugrah Samudro
Silmi Aprilia Andari Zakaria Gunada

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 MODULE 2.0
MACHINING PROCESS

1. OBJECTIVE

1.1 Students are able to understand about Machining Process.

1.2 Students are able to understand about CNC Machine Controller.
1.3 Students are able to understand about function buttons on CNC Machine Controller.

2. OUTLINES

2.1 CNC Machine Controller

2.2 Function Buttons on CNC Machine Controller
2.3 Standard Operations of CNC Machine Controller
2.4 Numerical Control

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 3. BASIC THEORY

3.1 CNC Machine Controller

CNC or Computer Numerical Controls are the operating system or brain of a CNC
system. A controller completes the all important link between a computer system and the
mechanical components of a CNC machine. The controller's primary task is to receive
conditioned signals from a computer or indexer and interpret those signals into mechanical
motion through motor output. There are several components that make up a controller and each
component works in unison to produce the desired motor movement.
The word “controller” is a generic term that may refer to one of several devices, but
usually refers to the complete machine control system. This system may include the protection
circuitry, stepper or servo motor drivers, power source, limit switch interfaces, power controls,
and other peripherals. Owners, operators, designers, and builders of CNC devices should
understand the tasks performed by these components and how they affect machine performance.

Figure 2.0.1 HAAS CNC Simulator (www.predator-software.com)

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 3.2 Function Buttons on CNC Machine Controller

A. General Machine Keys

In the following table can be seen in detail the functions of the general keys on
the CNC machine.
Table 2.0.1 General Machine Keys
Button Icon Function

Power On Turns CNC machine on.

Power Off Turns CNC machine tool off.

Stops all axis motion, stops spindle, tool

Emergency Stop
charger, and turns off coolant pump.

Jogs axis selected, also may be used to

scroll through programs, menu items
Jog Handle
while editing and also altering feeds and
speeds.

Starts program in run mode or graphics

Cycle Start
mode.

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 Table 2.0.1 General Machine Keys (cont.)
Button Icon Function

Stops all axis motion. Spindle will

Feed Hold
continue to turn.

Reset Stops machine, will rewind program.

Axis will return to machine zero and tool

Power Up/Restart
change will occur per Setting 81.

If a tool change is stopped in middle of

cycle an alarm will come up. Push the
Recover Recover button and follow the
instructions to bring the tool change
cycle to the beginning.

Control functions in HAAS machine tools are organized in three modes, those
are Setup, Edit and Operation. Access Modes using the mode keys as follows:
a. Setup : ZERO RET, HAND JOG keys. Provides all control features for
machine setup.
b. Edit : EDIT, MDI/DNC, LIST PROG keys. Provides all program editing,
management, and transfer functions.
c. Operation : MEM key. Provides all control features necessary to make a part.

Figure 2.0.2 Keypad Operation (Mill Series Training Manual - HAAS CNC Mill
Operator, 2013)

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B. Keyboard Introduction
a. Function Keys
In the following table can be seen in detail the functions of function
keys on the CNC machine.
Table 2.0.2 Function Keys
Button Icon Function
Perform different functions
F1 – F4 depending on which mode the
machine is in.
Will take machine Z position
readout at bottom of offset
Tool Offset Measure
screen and load it in to the
highlighted toll offset register.
After pressing Tool Offset
Measure button in a set up this
Next Tool
will select the next tool and
make a tool change.
Releases tool from spindle in
MDI, Zero Return or Handle
Tool Release mode. A button on the front of
the spindle will do the same
thing.
Records work coordinate
Part Zero Set offsets into the highlighted
register.

b. Jog Keys
In the following table can be seen in detail the functions of Jkeys on the
CNC machine
Table 2.0.3 Jog Keys
Button Icon Function
CHIP FWD (Chip Auger Turns the optional chip auger in
Forward) a direction that removes chips
from the work cell.
CHIP STOP (Chip Auger
Stop) Stops auger movement.

CHIP REV (Chip Auger

Reverse) Turns the chip auger in reverse.

Pressing this key will position

CLNT UP (Coolant Up) the coolant stream one position
higher.
CLNT DOWN (Coolant Pressing this key positions the
coolant stream one position
Down) lower.
AUX CLNT (Auxiliary Turns on the optional Through-
the-Spindle (TSC) coolant (in
Coolant) MDI mode).

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 Selects the X axis for
+X, -X (Axis) continuous motion when
depressed.
Selects the Y axis for
+Y, -Y (Axis) continuous motion when
depressed.
Selects the Z axis for
+Z, -Z (Axis) continuous motion when
depressed.
Selects the A axis. This key
selects the B axis when used
+A, -A (Axis) with the SHIFT key if the
machine is configured with a
fifth-axis option.
When this is pressed prior to
one of the jog keys given
Jog Lock above, the axis moves in a
continuous motion without the
need to hold down the axis key

c. Override Keys
In the following table can be seen in detail the functions of the override
keys on the CNC machine.
Table 2.0.4 Override Keys
Button Icon Function
Decreases current feed rate in
-10 Feed Rate
increments of 10 percent.
Resets the control feed rate to the
100% Feed Rate
programmed feed rate.
Increases current feed rate in
+10 Feed Rate
increments of 10 percent.

Hand wheel will control feed rate

Handle Control Feed Rate
at 1% increments.

-10 Spindle Decreases current spindle speed

in increments of 10 percent.

100% Spindle Sets the control spindle speed at

the programmed spindle speed.

+10 Spindle Increases current spindle speed in

increments of 10 percent.

Hand wheel will control feed rate

Handle Control Feed
at 1% increments

Starts the spindle in the clockwise

CW
direction.

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STOP Stop the spindle.

Starts the spindle in the

CCW
counterclockwise direction.
Limits rapid to 5 percent of
5% Rapid
maximum.
Limits rapid to 25 percent of
25% Rapid
maximum.

Limits rapid to 50 percent of

50% Rapid
maximum.

Allows rapid traverse to feed at

100% Rapid
its maximum.

d. Display Keys
In the following table can be seen in detail the functions of the display
keys on the CNC machine.
Table 2.0.5 Display Keys
Button Icon Function
Selects the active program pane
(highlights in white). In MDI/DNC
mode pressing a second time will allow
PRGM/CONVRS
access to VQC (Visual Quick Code)
and IPS (Intuitive Programming
System).
Selects the positions display window
(lower middle). Repeated pressing of
POSIT (Position)
the POSIT key will toggle through
relative positions in the Memory Mode.

Selects one of two offsets tables: Tool

OFFSET
Geometry/Wear and Work Zero Offset.

Ten different pages; use PAGE UP

and PAGE
DOWN
1. Operation Timers displays
Power-On Time,
Cycle Start Time, Feed Cutting
CURNT COMDS Time. Hitting ORIGIN will clear
any display that is highlighted by
the cursor.
2. Real time clock and date
3. System Variables, for
machines with Macro
Programming.

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 Table 2.0.5 Display Keys (cont.)
Button Icon Function
4. All Active Codes, displays
current and modal command
values.
5. Position information:
Machine, Distance to Go,
Operator, Work Coordinate.
6. Tool life, displays the usage of
each tool. Pressing ORIGIN will
clear the cursorselected display,
and pressing ORIGIN when the
cursor is at the top of a column
will clear the whole column.
7. Tool Load displays the Tool
Load Max % of each tool being
used. You can use the Limit%
column to set the maximum
spindle load for a particular tool.
8. Maintenance times for various
items may be loaded.
9. Advanced Tool Management
(Optional)
Tool Pot Table: Gives information on
which tool is in which Pot.
Displays messages and current active
alarms. Press right arrow key gives
ALARM/MESGS alarm history. Press right arrow key
again goes to the Alarm Viewer

A second press of PARAM/DGNOS

will show the diagnostics display.
PARAM/DGNOS The PAGE UP and PAGE DOWN
keys are then used to select one of
two different pages.
Displays settings - machine
parameters and control functions that
SETNG/GRAPH the user may need to turn on and off
or change to suit specific needs.

This provides information only

pertaining to that screen. Pressing the
HELP/CALC button again brings up
a tabbed menu. With tabulated
HELP/CALC screens highlighting tab and pressing
WRITE/ENTER key will open up
respective tab. Pressing the
CANCEL key will close the tab.
Help you solve values for feed rates
Milling and
SFM, RPM, and chip load under
Tapping different conditions.

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e. Cursor Keys
In the following table can be seen in detail the functions of the Cursor
keys on the CNC machine.
Table 2.0.6 Cursor Keys
Button Icon Function
Moves up/down one item, block or
Up/Down field.

Used to change displays or move

Page Up/ Down up/down one page when viewing a
program.
Will move the cursor to the top-most
Home item on the screen; in editing, this is
the top left block of the program.
Will take you to the bottom-most item
End of the screen. In editing, this is the last
block of the program.

f. Alpha Keys
In the following table can be seen in detail the functions of the displau
keys on the CNC machine Table 2.0.7 Cursor Keys
Button Icon Function
Provides access to the yellow
SHIFT characters shown in the upper left
corner of some of the alphanumeric
buttons on the keyboard
Enters the end-of-block character,
EOB which is displayed as a semicolon on
the screen and signifies the end of a
programming block. It also moves the
cursor to the next line.
These keys are used to define
( ) and (.) negative numbers and give decimal
posistion.
These symbols are accessed by first
+=#*[] pressing the SHIFT key and then the
key with the desired symbol

These are additional symbols,

accessed by pressing the SHIFT key,
,?%$!&@:
that can be used in parenthetical
comments.

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g. Numeric Keys
In the following table can be seen in detail the functions of the numeric
keys on the CNC machine Table 2.0.8 Numeric Keys
Button Icon Function
The Cancel key will delete the last
CANCEL character put into the Input Section of
the control display.
Is used to format comments placed
SPACE into the Input Section of the control
display.
General purpose Enter key. It inserts
code from the input section into a
program when the program display is
WRITE/ ENTER in EDIT mode. With offsets pages
active, pressing the WRITE/ENTER
key adds a number in the Input Section
to the highlighted cell.

h. Mode Keys
In the following table can be seen in detail the functions of the mode
keys on the CNC machine.
Table 2.0.9 Mode Keys
Button Icon Function
The edit mode is used to make changes
EDIT
in a program stored in memory.
Enters commands keyed into the input
panel in lower left pane of CRT after
INSERT
the cursor highlighted word in a
program.
Highlighted words are replaced by text
ALTER
input into the input panel.
Highlighted words are deleted from a
DELETE
program.

UNDO Will undo up to the last 9 edit changes.

While in the edit mode pressing F1

F1 KEY
will bring up an edit pop up window.
Gives options on changing line
MODIFY
numbers.
Will perform a search and gives the
SEARCH
option of replacing text.
Gives options of creating new
program, selecting a program from list
PROGRAM to edit, duplication of programs,
switching from left to right side of
window panes.

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 Table 2.0.9 Mode Keys (cont.)
Button Icon Function
When a program is being run
BACKGROUND EDIT pushing the edit will bring up the
Background Edit pane in the
Main Display Pane.
The memory mode is the mode
MEM used when running the machine
and making a part.
When the machine is in SINGLE
BLOCK mode only one block of
the program is executed every
SINGLE BLOCK time the cycle start button is
depressed. Used when first test
running a program or temporarily
stopping a program when it is
running.
Used to check machine
movement without cutting a part.
DRY RUN
In dry run the machine runs at one
feed rate.
When OPTION STOP is
depressed program will stop at
OPTION STOP any M01 which is in the program.
Normally M01s are placed after a
tool is run in a program.
When this button is depressed
BLOCK DELETE any block with a slash (/) in it is
ignored of skipped.
(MANUAL DATA INPUT
MDI / DNC mode) Usually short programs
are written in MDI but are not put
into memory.

COOLNT Turns coolant on and off

manually.
Rotates and locks spindle to
specific angle. Used when lining
ORIENT SPINDLE up tools where spindle
orientation may be a issue such as
boring heads.
Rotates turret to next tool and
performs tool change - also used
ATC FWD to call up specific tools or pots.
Enter tool number (T1) and press
ATC FWD.

HAND JOG Puts machine in jog mode for set

ups.
On pressing position display
ZERO RET becomes highlighted in Zero
Return mode.
Returns all axes to machine home
ALL similar in similar fashion as a
Power Up/Restart.

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 Button Icon Function

ORIGIN Sets selected displays to zero or

other functions.
Returns a single axis to machine
SINGL home. Select desired axis (X, Y,
or Z) then press Singl axis button.
Rapid motion to machine home;
HOME/G28 will make a rapid move in all axes
at once - may also be used for a
rapid home in one-axis.
This is the program that will run
the CNC machine in the Memory
SELECT PROG mode. Use in the Edit mode in the
Main Display will enter selected
program in the Main Display
pane for editing.
Will send a selected program or
SEND programs out thru
RS-232 serial port
Will erase highlighted program
or programs. A prompt will
ERASE PROG appear asking if you want to
delete selected program asking
for Y/N.

3.3 Standard Operations of CNC Machine

A. How to turn on HAAS Control Simulator

1. Connect HAAS Control Simulator to the power supply.
2. Press Emergency Stop button before turn on the simulator.
3. Press Power On button to turn on the simulator.
4. Press Left button to choose Mill Operation or Right button to choose Lathe
Operation.

Figure 2.0.3 Simulator Display

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5. Follow the instruction from the screen and wait until HAAS machine is ready
to start, release Emergency Stop button.

Figure 2.0.4 Screen of Setup Zero

6. Press Reset to enable servos.

Figure 2.0.5 Screen of Enable Servos

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7. Press Power Up button, wait until the machine configure the position (x,y,z)
machine.

Figure 2.0.6 Screen of Zero All Axes Process

8. The operation is ready to use.

Figure 2.0.7 Screen of Operation Ready to Use

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B. How to turn off HAAS Control Simulator
1. To turn off the simulator machine, press the Emergency Stop.
2. Then, press Power Off button and wait until the simulator turn off.

C. How to setting the Tool Offset and Work Offset

Tool and Work offsets must be set before we run the operation. Enter values for
each tool used on the Setup screen. The tool offsets will be referenced when that tool is
called in the operation. On each of the following interactive screens the user is asked to
enter data needed to complete common machining tasks. When all the data has been
entered, pressing “Cycle Start” to begin the machining process.
a. Tool Offset
1. Press MDI DNC → OFFSET (Tool Offset default = 0

Figure 2.0.8 Tool Offset Menu

2. Input Geometry (Length and Diameter), Flutes, Actual Diameter, and Tool
Type (depends on the measurement)

Figure 2.0.9 Tool Offset Menu

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 b. Work Offset
1. Press OFFSET ( Work Zero Offset default = 0 )

Figure 2.0.10 Work Zero Offset Menu

2. Input X Axis, Y Axis, Z Axis (depends on the measurement)

Figure 2.0.11 Work Zero Offset Menu

D. How to create a new program

1. Tocreate a new program, press the LIST PROG.
2. Input your program number into input panel type “O + the number program that
haven’t exist yet”.
3. Press WRITE/ENTER.
4. Then, press EDIT and input your NC Code.

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E. How to access a list of programs that already exist in the internal memory
1. To access a list of programs that already exist in the internal memory, press LIST
PROG → choose MEMORY, and then press ENTER.

Figure 2.0.12 List Program Menu

2. Use the Cursor Keys or the Handle Jog to find some numbers of program that
doesn’t exist yet. To make a new program, type “O (alphabet) + the number of
program that haven’t exist yet” (ex: O40), and then press ENTER.

Figure 2.0.13 List of Program

Press EDIT to make or edit codes for the program, and then type the required
codes (it’s not necessary to use a SPACE), after writing a line of codes press
WRITE/ENTER (to delete a code before ENTER was pressed, press CANCEL,
and to delete a code after ENTER was pressed, press DELETE).

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 3.4 Numerical Control

A machine with computer technology are controlled by a numerical code. A software to

translate form code language into movement axis are usually called Machine Control Unit
(MCU). This language which called programming language for communication between
machine and operator using a numerical, alphabetical, and symbol. Programming language in
a CNC machine known as Numerical Control Code (NC-Code). Below are the mostly used NC
Code to operating a machine :
A. G-Code
G-Code is used to command specific actions for the machine such as movements of the
machine. Function of G-Code are already in International Standardization.
Table 2.0.10 G-Code
Code Description
G00 Rapid positioning
G01 Linear interpolation
G02 Circular interpolation, clockwise
G03 Circular interpolation, counterclockwise
G04 Dwell
G05 Spline definition
G06 Spline interpolation
G07 Imaginary axis designation
G09 Exact stop check, non-modal
G10 Programmable data input
G11 Data write cancel
G12 Full-circle interpolation, clockwise
G13 Full-circle interpolation, counterclockwise
G17 XY plane selection
G18 ZX plane selection
G19 YZ plane selection
G20 Programming ininches
G28 Return to home position (machine zero, a.k.a machine reference point)

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 Table 2.0.10 G-Code (cont.)
Code Description
Return to secondary home position (machine zero, a.k.a machine
G30
reference point)
G31 Skip function (used for probes and tool length measurement systems)
G32 Single-point threading, longhand style (if not using a cycle, e.g., G76)
G33 Constant-pitchthreading
G33 Single-point threading, longhand style (if not using a cycle, e.g., G76)
G34 Variable-pitch threading
G40 Tool radius compensation off
G41 Tool radius compensation left
G42 Tool radius compensation right
G43 Tool height offset compensation negative
G44 Tool height offset compensation positive
G45 Axis offset single increase
G46 Axis offset single decrease
G47 Axis offset double increase
G48 Axis offset double decrease
G49 Tool length offset compensation cancel
G50 Define the maximum spindle speed
G50 Scaling function cancel
G50 Position register (programming of vector from part zero to tool tip)
G52 Local coordinate system (LCS)
G53 Machine coordinate system
G54 Zero offset #1
G55 Zero offset #2
G56 Zero offset #3
G57 Zero offset #4
G58 Zero offset #5
G59 Zero offset #6
G62 Automatic corner override
G64 Default cutting mode (cancel exact stop check mode)
G68 Rotate coordinate system.

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 Table 2.0.10 G-Code (cont.)
Code Description
G69 Turn off coordinate system rotation.
G70 Finishing cycle (including contours)
G71 Stock removal cycle (Z-axis emphasis)
G72 Stock removal cycle (X-axis emphasis)
G73 Irregular part stock removal cycle
G74 Face grooving cycle for turning
G75 Peck grooving cycle for turning
G76 Threading cycle for turning, multiple repetitive cycle
G80 Cancel canned cycle
G81 Drilling to final depth canned cycle
G82 Drilling cycle with dwell
G83 Peck drilling cycle
G84 Tapping cycle,righthand thread, M03 spindle direction
G85 Boring cycle, feed in/feed out
G86 Boring cycle, feed in/spindle stop/rapid out
G87 Boring cycle, backboring
G88 Boring cycle, feed in/spindle stop/manual operation
G89 Boring cycle, feed in/dwell/feed out
G90 Absolute programming
G91 Incremental programming

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B. M-Code
M-code are codes non-axis commands that used in CNC to define function of the
machine. In application functions of Numerical, alphabetical and symbol codes are various,
depends on the system and machine control type but still it used in a same principle.

Table 2.0.11 M-Code

Code Description
M00 Unconditional stop
M01 Conditional stop
M02 End of program

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 Table 2.0.11 M-Code (cont.)
Code Description
M03 Spindle clockwise
M04 Spindle counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant On
M19 Spindle orientation
M20 Start oscillation (configured by G35)
M21 End oscillation
M30 End of program
M00 Unconditional stop

C. A-Code
Alarm code (A-code) is a sign when machine found incorrect program. This
code help to stop machining process automatically if there are not corrections.
Furthermore this code will decrease possibility of machine damage.

Table 2.0.12 A-Code

Code Description
A00 Command G & M false
A01 Command radius M99 false
A02 X Value False
A03 F Value False
A04 Z Value False
A05 Less command M30
A06 Extreme spindle rotation
A08 Disk full/empty A09 Cannot found program
A10 Disk Locked
A11 Load Disk false
A12 False Checking
A13 Unit false in object
A14 Unit false
A15 H rate False

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 Table 2.0.12 A-Code (cont.)
Code Description
A17 Subroutine program False
A00 Command G & M false
A01 Command radius M99 false
A02 X Value False
A03 F Value False
A04 Z Value False

D. Frequently Used Code

Table 2.0.13 Frequently Used Code
Code Description
G00 Rapid positioning
G01 Linear interpolation
G02 Circular interpolation, clockwise
G03 Circular interpolation, counterclockwise
Return to secondary home position (machine zero, a.k.a machine
G30
reference point)
G54 Zero offset #1
G70 Finishing cycle (including contours)
G71 Stock removal cycle (Z-axis emphasis)
G72 Stock removal cycle (X-axis emphasis)
G90 Absolute programming
G91 Incremental programming

Conditional stop
M01
M02 End of program
M03 Spindle clockwise
M04 Spindle counterclockwise
M05 Spindle stop
M06 Tool change
M98 Sub Program Call
M99 Sub Program Return or Loop
M30 End of program

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SCAN HERE FOR UNDERSTANDING THIS MODULE

Tutorial The HAAS CNC Control Panel

https://www.youtube.com/watch?v=ipEVaN4h6Wo

Tutorial How to Used HAAS Simulator

https://youtu.be/VzAeMP3eplw

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 4. REFERENCES

Daviddelaney. (2014). What is a CNC Controller and How Does It Work? Retrieved from
EZCUT CNC Machitech Automation: http://www.ezcutcnc.com/cnc-controller-work/
Hearn, W. (n.d.). CNC Controls. Retrieved from WD Hearn Machine Tools:
http://wdhearn.co.za/product/cnc-controls
Inc, P. S. (n.d.). Haas CNC Software 3D Machine Simulation & Verification 2-5 Axis Mills,
Lathes, Mill/Turns, Lasers, Waterjets & Routers. Retrieved from Predator Software
Inc: http://www.predator-software.com/Predator_Virtual_CNC_Software_Haas_CNC.htm
Outlet, H. F. (2013). Mill Series Training Manual - HAAS CNC Mill Operator. Division of
Productivity Inc.

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